JP2014177270A - Sealed aluminum honeycomb structure reinforcing member - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a structure reinforcing member for a hollow structural member of a vehicle body having both characteristics of weight reduction and strength enhancement, and provide a reinforcing method of a hollow structural member.SOLUTION: A vehicle body includes a hollow structural member having an inner surface. The hollow structural member includes first metal or a metal alloy. A structure reinforcing member is arranged in the hollow structural member, and is provided with a reinforcing material. The reinforcing material contains second metal or a metal alloy different from the first metal or the metal alloy. A clearance is arranged between the reinforcing material and the inner surface of the structural member. An adhesive is fixed to the reinforcing material. The adhesive is substantially dry to touch before activation, and can be activated to expand to the inner surface to fill at least a part of the clearance. A frame is arranged between the reinforcing material and the inner surface of the structural member to maintain the clearance before expansion of the adhesive, and the frame is fixed to the reinforcing material. The frame is formed so as to isolate the reinforcing material from the hollow structural member.

Description

  The present invention relates to a vehicle body constituted by a hollow member provided with a reinforcing material.

  In vehicle design, vehicles tend to be lighter in order to improve fuel efficiency. At the same time, the structural performance standards required by manufacturers are required to be stricter. When a light-weight hollow cross-section member used for forming a vehicle body is used, it is necessary to add a reinforcing material to various locations of the vehicle body. As is well known, the body is generally subjected to an electrodeposition coating process in which an anti-corrosion coating is formed on the body by electrolysis through the body through an anti-corrosion fluid tank. Subsequently, the car body is heated to bake the coating onto the metal. Therefore, it is desirable that the reinforcement does not interfere with the anticorrosion coating on the inner surface of the hollow member by the electrodeposition coating process.

  It is known to provide a longitudinal reinforcing structure in a hollow cross-section member of a vehicle body. This structure is typically provided with an expandable adhesive on two surfaces, which expands when heated to connect the beam to the two opposing walls of the hollow member. Is possible. However, this technique is not suitable for use in the electrodeposition coating process described above because it can interfere with proper electrodeposition coating over the entire surface and locally cause corrosion areas. Another known reinforcement is a lightweight and high strength aluminum honeycomb. However, it is difficult to isolate the aluminum and the steel hollow member in order to accurately position the reinforcing material in the hollow member and prevent the honeycomb from being filled with the anticorrosive fluid and increasing its weight. It is also known to provide a foamable plastic molding in the hollow member, which foams when subjected to heat, for example as provided by the baking step of the electrodeposition coating process, and has a cross-section. It is possible to provide a foam wall that fills the surface with sound absorption. These inserts can be used to provide acoustic walls and seals.

  According to one concept of the present invention, the vehicle body includes a hollow structural member having an inner surface. The hollow structural member includes a first metal or a metal alloy. A structural reinforcing member is disposed in the hollow structural member. The structural reinforcing member includes a reinforcing material including a second metal or metal alloy different from the first metal or metal alloy. A gap is provided between the reinforcing material and the inner surface of the hollow structural member. An adhesive is fixed to the reinforcing material. The adhesive is substantially dry to the touch prior to activation, but can be activated to expand toward the inner surface to fill at least a portion of the gap. A frame is arranged between the reinforcing material and the inner surface of the hollow structural member in order to maintain a gap before the adhesive expands, and is fixed to the reinforcing material. The frame is adapted to insulate the reinforcement from the hollow structural member.

  According to another concept of the present invention, a structural reinforcing member for a vehicle body including a hollow structural member having an inner surface includes a reinforcing material that can be inserted into the hollow structural member with a gap between the reinforcing material and the inner surface. . The reinforcing material includes a honeycomb structure having a plurality of openings. The stiffener is disposed within the hollow structural member such that the opening is oriented substantially perpendicular to the longitudinal axis of the hollow structural member. The adhesive is disposed so as to close the opposed open ends of the plurality of openings of the honeycomb structure, and is directly fixed to the reinforcing material. The adhesive is substantially dry to the touch prior to activation, but can be activated to expand toward the inner surface to fill at least a portion of the gap. In order to maintain a gap before expansion of the adhesive, a frame is disposed between the reinforcing material and the inner surface of the hollow structural member, and is fixed to the reinforcing material. A portion of the frame is configured to substantially match the shape of the inner surface of the hollow structural member.

  According to yet another concept of the present invention, a method for reinforcing a hollow structural member of a vehicle includes the steps of providing a reinforcing material comprising a honeycomb structure having a plurality of openings, and expanding outward from the reinforcing material to form a hollow structure. Fixing the activatable adhesive to the stiffener to engage a portion of the inner surface of the member; and a frame having a portion configured to substantially match the shape of the inner surface of the hollow structural member. Fixing, inserting a reinforcing material together with the frame into the hollow structural member, and providing a gap between the adhesive and the inner surface of the hollow structural member before activating the adhesive.

Schematic of a part of the vehicle body. FIG. 2 is a cross-sectional perspective view of one aspect of the first structural member of the vehicle body portion of FIG. 1 along line 2-2 of FIG. 1 including an exemplary reinforcing member according to the first embodiment of the present disclosure. The figure which shows the structural reinforcement member of FIG. 2 before attaching to a 1st structural member. The figure which shows the structural reinforcement member of FIG. 2 fixed to the 1st structural member. FIG. 3 is a perspective view of the structural reinforcing member in FIG. 2. FIG. 6 is an exploded partial perspective view of the structural reinforcing member of FIG. 5. 1 is a cross-sectional perspective view of a second structural member of the vehicle body portion of FIG. 1 taken along line 7-7 of FIG. 1 including an exemplary reinforcing member according to aspects of a second embodiment of the present disclosure. The figure which shows the structural reinforcement member of FIG. 7 before attaching to a 2nd structural member. The figure which shows the structural reinforcement member of FIG. 7 fixed to the 2nd structural member. The perspective view of the structural reinforcement member of FIG. FIG. 11 is an exploded partial perspective view of the structural reinforcing member of FIG. 10. FIG. 8 is a cross-sectional view of a second structural member similar to FIG. 7 including an exemplary reinforcing member according to a third embodiment of the present disclosure. The perspective view of the structural reinforcement member of FIG. FIG. 6 is a cross-sectional view of another aspect of the first structural member of the vehicle body portion of FIG. 1 including an exemplary reinforcing member according to a fourth embodiment of the present disclosure. The disassembled partial perspective view of the structural reinforcement member of FIG. FIG. 10 is an exploded perspective view of an exemplary reinforcing member according to a fifth embodiment of the present disclosure. The perspective view of the structural reinforcement member of FIG. The expansion perspective view of the 1st attachment part of the structural reinforcement member of FIG. The expansion perspective view of the 1st attachment part of the structural reinforcement member of FIG. The expansion perspective view of the 1st attachment part of the structural reinforcement member of FIG. The expansion perspective view of the 1st attachment part of the structural reinforcement member of FIG. The expansion perspective view of the 2nd attachment part of the structural reinforcement member of FIG. The expansion perspective view of the 2nd attachment part of the structural reinforcement member of FIG. FIG. 18 is a perspective view of the structural strengthening member of FIG. 17 attached to yet another aspect of the first structural member of the vehicle body portion of FIG. 1. FIG. 18 is a perspective view of the structural strengthening member of FIG. 17 attached to yet another aspect of the first structural member of the vehicle body portion of FIG. 1. FIG. 14 is an exploded perspective view of an exemplary reinforcing member according to a sixth embodiment of the present disclosure. The perspective view of the structural reinforcement member of FIG. The perspective view of the structural reinforcement member of FIG. The expansion perspective view of the 1st attachment part of the structural reinforcement member of FIG. The expansion perspective view of the 1st attachment part of the structural reinforcement member of FIG. The expansion perspective view of the 2nd attachment part of the structure reinforcement member of FIG. The perspective view of the reinforcement member of FIG. 26 attached to another aspect of the 2nd structural member of the vehicle body part of FIG. FIG. 33 is a cross-sectional perspective view of FIG. 32.

  It should be understood that the description and drawings herein are exemplary only, and that various modifications and changes may be made to the disclosed structures without departing from the disclosure. In general, illustrations of exemplary structural reinforcement members are not to scale. In addition, the various specific components of the exemplary structural reinforcement members disclosed herein are merely technical terms that may vary from manufacturer to manufacturer and should not be considered as limiting the present disclosure. I want you to recognize that.

  Referring now to the drawings in which like numerals refer to like parts in the several views, FIG. A part of the vehicle body 100 is formed of a generally hollow structural member such as a side sill 102, an A pillar 104, and a B pillar 106 joined so as to define a frame 108. Each of the structural members 102, 104, 106 is reinforced with an exemplary structural reinforcement member located in the hollow or cavity portion of the structural member, as described in further detail below. When the structural reinforcement member is properly positioned within the structural members 102, 104, the reinforcement member is prevented from interfering with the anticorrosion coating on the inner surface of the hollow structural members 102, 104 by the electrodeposition coating process.

  2-4 illustrate an exemplary structural member or side sill 102 with an exemplary reinforcing member 120 installed. The structural member or side sill 102 is formed of an outer panel member 122 joined to an inner panel member 124, and the outer and inner panel members 122, 124 define an elongated cavity 126. The outer panel member 122 includes a side wall 130, an upper wall 132, and a lower wall 134. The flange 136 extends outward from the end portion of the upper wall 132, and the flange 138 extends outward from the end portion of the lower wall 134. Similarly, the inner panel member 124 includes a side wall 140, an upper wall 142, and a lower wall 144. The flange 146 extends outward from the end portion of the upper wall 142, and the flange 148 extends outward from the end portion of the lower wall 144. The flanges 136, 138 of the outer panel member 122 are secured to the corresponding flanges 146, 148 of the inner panel member 124 (eg, by welding). As shown, the exemplary side sill 102 further includes a longitudinally extending channel 160 defined in the sidewall 130 of the outer panel member 122. The structural member or side sill 102 includes a first metal or metal alloy and may be formed of steel or alloy steel.

  The exemplary structural strengthening member 120 is placed in the cavity 126 of the hollow structural member or side sill 102. Referring to FIG. 5, the reinforcing member 120 includes a reinforcing material 170, an adhesive 172 fixed to the reinforcing material 170, and a frame 174 fixed to the reinforcing material 170. The reinforcing material 170 includes an upper surface 180, a lower surface 182, an outer side surface 184, and an inner side surface 186. Referring to FIG. 6, the reinforcing material 170 includes a honeycomb structure 190 in which a plurality of openings 192 are defined. The honeycomb structure 190 has a shape that substantially matches the cross section of a portion of the hollow structural member 102 that is reinforced by the reinforcing material 170. The reinforcement 170 includes a second metal or metal alloy that is different from the first metal or metal alloy of the side sill 102, and according to the concepts of the present invention, the reinforcement 170 may be formed of aluminum or an aluminum alloy. In the illustrated embodiment, the adhesive 172 is provided on both the outer side 184 and the inner side 186 of the reinforcement, and the reinforcement places the adhesive 172 on both sides of the opening 192 in the honeycomb structure 190.

  The frame 174 is attached to one of the side surfaces of the stiffener 170, and in the illustrated embodiment, the frame is attached to the outer side surface 184 via an adhesive 172. The frame 174 is configured to substantially match the shape of the hollow structural member or the inner surface of the side sill 102 and is configured to be attached to a portion of the inner surface of the side sill 102. According to the inventive concept, the frame 174 includes a side surface 200 that has at least one protrusion 202 extending outwardly from the side surface 200. The protrusion 202 has a size that can be received in a channel 160 defined in the outer panel member 122 of the side sill 102. As shown, the frame 174 includes a plurality of spaced apart protrusions 202 arranged along the side surface 200, but this is not essential. Alternatively, the frame 174 comprises a single elongated protrusion 202 that extends substantially along the longitudinal direction of the frame side 200. The adhesive 172 is provided along the outer surface of each protrusion 202, and in the illustrated embodiment, the belt-like adhesive 172 is provided on the protrusion 202 in a direction perpendicular to the frame side surface 200. The frame 174 may be formed of various materials. Materials include, by way of example, polymeric materials (eg, plastics, elastomers, thermoplastics, thermosets, combinations thereof, etc.). The material of the frame 174 may be reinforced with an inorganic material, a fiber material (for example, glass, carbon, or nylon fiber), a combination thereof, or the like. When the materials of the side sill 102 and the reinforcing material 170 are different, the inner surface of the side sill 102 and the reinforcing material 170 come into contact with each other, which may cause galvanic corrosion. The material of the frame 174 is selected to insulate the reinforcement 170 from the inner surface of the side sill 102 and galvanic corrosion is prevented.

  Referring back to FIGS. 3 and 4, the reinforcing member 120 is disposed within the cavity 126 of the side sill 102 and the protrusion 202 is slidably received in a channel 160 defined in the side wall 130 of the outer panel member 122. The The honeycomb structure 190 is disposed in the side sill 102 such that the opening 192 is oriented substantially perpendicular to the longitudinal axis of the side sill. Again, the adhesive 172 is attached to the open end of the honeycomb structure 190 so that an anticorrosive fluid such as an electrodeposition paint cannot pass through the adhesive. A gap 210 is provided between the adhesive 172 installed on the side surface 200 of the frame 174 and the inner surface of the outer panel member 122, and the corresponding gap 212 is fixed to the inner side surface 186 of the reinforcing material 170. It is provided between the agent 172 and the inner surface of the inner panel member 124. By providing the gaps 210 and 212, the anticorrosion fluid flows between the reinforcing member 120 and the inner surface of the side sill 102.

  Adhesive 172 is selected to be activatable under the desired conditions. As used herein, activatable means that the adhesive 172 becomes softened (eg, melted), cured, expanded, foamed, or combinations thereof when exposed to certain conditions. To do. Thus, according to one embodiment, the adhesive 172 may be a heat activated and / or epoxy based resin having foamable properties. Of course, the adhesive 172 may be activated by other conditions or stimuli. The choice of adhesive 172 to use is typically determined according to the performance requirements and the economic aspects of the particular application and requirements. According to the present disclosure, the adhesive is substantially dry to the touch prior to activation, but expands toward the inner surface of the side sill 102 when the vehicle body 100 is sent to the painting process and the adhesive is exposed to high temperatures. To fill at least a portion of the gaps 210, 212. Further, the adhesive 172 has high ductility for favorably dispersing the load along the entire longitudinal axis of the reinforcing material 170. In order to secure the adhesive 172 to the reinforcement 170, the adhesive can be preheated to a temperature suitable for making it tacky, but that temperature is a low temperature that does not exceed the curing or expansion temperature of the adhesive. belongs to.

  FIGS. 7-9 show a reinforcing member 220 disposed within a hollow structural member or A-pillar 104. As illustrated, the A pillar 104 includes an outer panel member 222, an inner panel member 224, and a reinforcing material 226. The outer panel member 222 includes a side wall 230, an upper wall 232, and a lower wall 234. The flange 236 extends from the end portion of the upper wall 232, and the flange 238 extends from the end portion of the lower wall 234. The inner panel member 224 includes a sidewall 240 having flanges 242 and 244 extending from the upper end portion and the lower end portion of the sidewall 240, respectively. The reinforcing member 226 is interposed between the outer panel member 222 and the inner panel member 224 and has a shape similar to the shape of the outer panel member 222. In particular, the stiffener 226 includes a sidewall 250 having upper and lower flanges 252, 254 that extend outwardly from both edge portions of the sidewall 250. To form the A-pillar 104, the outer panel member 222 and the inner panel member 224 are arranged such that the upper flange 252 is sandwiched between the flanges 236 and 242 and the lower flange 254 is sandwiched between the flanges 238 and 244. A reinforcing material 226 is provided between the two. The flanges are then secured together, for example by welding. The A-pillar 104 is defined with an elongated channel 260 sized to receive the reinforcing member 220.

  Referring to FIGS. 10 and 11, the reinforcing member 220 includes a reinforcing material 270 and an adhesive 272 directly fixed to the reinforcing material. Adhesive 272 is substantially dry to touch prior to activation, but is similar to adhesive 172 so that it can be activated to expand toward the inner surface of A-pillar 104 during the painting process. Is. Similar to the reinforcement 170, the reinforcement 270 includes a honeycomb structure 280 having a plurality of openings 282. The honeycomb structure 280 has a shape that substantially matches the cross-section of the portion of the hollow structural member 104 that is reinforced by the reinforcing material, and the adhesive 272 has a plurality of openings 282 in the honeycomb structure 280 so that the anticorrosive fluid does not flow therethrough. It arrange | positions so that both the open ends may be closed. A pillar 104 is formed of a first metal or metal alloy such as steel or alloy steel, and honeycomb structure 280 of reinforcing member 220 is formed of a second metal or metal alloy such as aluminum or aluminum alloy. Adhesives 272 provided on both sides isolate the honeycomb structure 280 from the inner surface of the A pillar 104.

  FIG. 8 shows the reinforcing member 220 inserted into the cavity 260 of the A pillar 104 prior to activation of the adhesive 272. A gap 290 is provided between the adhesive 272 fixed on one side of the honeycomb structure 280 and the inner surface of the reinforcing material 226, and the adhesive 272 fixed on the other side of the honeycomb structure 280 and the inner surface of the reinforcing material 226. Corresponding gaps 292 are provided in between. The reinforcement 270 is disposed in the cavity 260 such that the opening 282 of the honeycomb structure 280 is oriented substantially perpendicular to the longitudinal axis of the A pillar 104. FIG. 9 shows the A-pillar 104 after the painting process. The adhesive 272 expands toward the inner surface of the reinforcing material 226 and fills at least a part of the gaps 290 and 292 provided between the reinforcing member 220 and the inner surface of the reinforcing material 226. Further, the reinforcing member 220 has substantially the axis of the opening 282 so that the electrodeposition paint taken into the opening 282 of the honeycomb structure 280 can escape from the honeycomb structure before the activation of the adhesive 272. A bore 300 is provided that extends through the honeycomb structure 280 in a vertical direction (see FIG. 10).

  In order to securely install the reinforcing member 220 in the cavity 260 defined by the A pillar 104, the reinforcing material 270 and the reinforcing material 226 of the A pillar 104 are maintained in order to maintain the gaps 290 and 292 before the adhesive 272 is expanded. The frame 302 is disposed between the inner surface and the reinforcing member 270. As shown in FIGS. 12 and 13, the frame 302 includes a first frame component 304 and a second frame component 306. The frame 302 is disposed on the reinforcement 270 such that the frame 302 is substantially perpendicular to the adhesive 272 that is secured to both sides of the honeycomb structure 280. Specifically, the first frame component 304 is provided between the reinforcing material 226 and the reinforcing material 270 of the A pillar 104, and the second frame component 306 includes the inner panel member 224 and the reinforcing material 270 of the A pillar 104. Between. An adhesive 308 is used to secure the first and second frame components 304, 306 to the stiffener 270. Adhesive 308 may be similar to adhesive 272 such that the adhesive is heat activated, but this is not required.

  The first frame component 304 includes at least one spacer member 310 that extends outwardly from the first frame component to engage the inner surface of the reinforcement 226 of the A pillar 104. As shown, the spacer member 310 is comprised of a plurality of spaced apart protrusions, but this is not essential. Similarly, the second frame component 306 includes at least one spacer member 312 that extends outwardly from the second frame component to engage the inner surface of the inner panel member 224 of the A pillar 104. Similar to the spacer member 310, the spacer member 312 is constituted by a plurality of spaced protrusions. It should be appreciated that other configurations of the spacer members 310, 312 are envisioned. For example, each of the spacer members 310, 312 is configured by a single elongated protrusion that extends along the respective longitudinal direction of the first and second frame components 304, 306.

  14 and 15 show another configuration of the side sill 320 of the frame 108 of the vehicle body 100. FIG. According to this aspect, the side sill 320 includes the outer panel member 322 fixed to the inner panel member 324 to form the cavity 326. However, unlike the side sill 102, no channel is provided on one of the panel members 322, 324 to securely place the exemplary reinforcing member 330 in the cavity 326. Similar to the reinforcing member described above, the reinforcing member 330 includes a reinforcing member 332 including a honeycomb structure 334 having a plurality of openings (not shown). The adhesive 336 is directly fixed to the reinforcing material 332 and is disposed so as to close both ends of the plurality of openings of the honeycomb structure 334. Adhesive 336 may have properties similar to adhesives 172 and 272.

  The frame 340 is fixed to the reinforcing material 332 and is disposed substantially perpendicular to the adhesive 336. The frame 340 is installed between the reinforcing member 332 and the inner surface of the side sill 320 in order to maintain a gap between the reinforcing member 330 and the inner surface before the adhesive 336 expands. The frame 340 includes a first frame component 342 and a second frame component 344. The first frame component 342 includes a base portion 350 and side walls 352 and 354 extending from the base portion 350. Engagement members 356 and 358 are provided on the side walls 352 and 354, respectively. The intervals between the side walls 352 and 354 are such that the reinforcing material 332 can be installed together with the adhesive 336 on the base 350 in a state where the engaging members 356 and 358 are engaged with the reinforcing material 332. Spacer member 360 extends from base 350 and is dimensioned to engage the inner surface of side sill 320. Similarly, the second frame component 344 includes a base 370, opposing side walls 372, 374 configured to engage the stiffener 332, and a spacer member 380 sized to engage the inner surface of the side sill 320. And comprising. Similar to the previous embodiment of the reinforcing member, the frame 340 is configured to substantially match the shape of the inner surface of the side sill 320, and the adhesive allows the electrodeposition paint to flow freely again along the inner surface of the side sill 320. Prior to expansion of 336, the gap between the reinforcing member 330 and the inner surface of the side sill 320 is maintained.

  FIGS. 16 and 17 show another embodiment of a reinforcing member 400 for insertion into a hollow structural member or side sill 102. Similar to the reinforcement member 120, the reinforcement member 400 comprises a reinforcement 402 comprising a honeycomb structure 404 having a plurality of openings oriented substantially perpendicular to the longitudinal axis of the side sill 102. Adhesive 406 is secured to the outer and inner sides 410, 412 of the reinforcement 402 and is similar to the adhesive 172. A frame 420 configured to substantially match the shape of the inner surface of the side sill 102 is fixed to the reinforcing member 402 and includes a base wall 422 and opposing side walls 424 and 426 connected to the base wall. . According to one aspect, each of the side walls 424, 426 can be hinged to a base wall 422 that facilitates assembly of the frame 420.

  The base wall 422 includes longitudinal members 430 and 432 that are spaced apart from each other, and a plurality of transverse members 434 that are spaced apart from each other across the longitudinal members 430 and 432. Around a selected portion of the circumference of the base wall 422, a flange 440 extending outward to engage with the reinforcing member 402 is provided. The side wall 424 may include a plurality of spaced apart notches 450 arranged along the length of the side wall, and around a selected portion of the periphery of the base wall to engage the stiffener 402. And a flange 452 extending outward. Sidewall 426 is defined by longitudinal members 460, 462 spaced apart from each other and a plurality of transverse members 464 that span between the longitudinal members. Similar to the side wall 424, a flange is provided extending outwardly to engage the stiffener 402 along at least a portion of the circumference of the side wall 426.

  In order to assemble the reinforcing member 400, the reinforcing member 402 is disposed on the base wall 422 of the frame 420 together with the adhesive 406 fixed to the reinforcing member. Side walls 424, 426 hinged to the base wall 422 swing relative to the base wall 422 and are substantially perpendicular to the base wall. In this vertical position, the side walls 424, 426 are adjacent to the adhesive 406 and the flanges 452, 466 engage the stiffener 402. As shown in FIGS. 16-18, the exemplary frame 420 further includes brackets 470 that are attached to the sidewalls 424,426. Specifically, a plurality of first lock members 480 are provided on the side wall 424, and a plurality of second lock members 482 are provided on the side wall 426. First and second locking members 480, 482 assist in attaching bracket 470 to side walls 424, 426. In the illustrated embodiment, the first and second locking members are interference fit fasteners (eg, arrowhead fasteners) attached to flanges 452, 466 provided on the side walls 424, 426, respectively. First and second locking members 480, 482 protrude through corresponding openings 490 in bracket 470. With the bracket 470 secured to the side walls 424, 426, the frame 420 substantially surrounds the reinforcement 402 and the adhesive 406 secured to the reinforcement.

  Hereinafter, referring to FIGS. 19 to 21, as described above, the base wall 422 of the frame 406 includes the transverse member 434. A clip housing 500 is provided on the selected transverse member 434. Each of the clip housings 500 includes an upper wall 502 and opposing side walls 504 and 506. Side wall 504 has a groove opening 510 configured to hold a fastener or clip 516. The fastener 516 is fixed to the opening 520 provided in the reinforcing member 522 associated with the side sill 102. To further secure the frame 420 to the cavity 126 of the side sill 102, each of the brackets 470 includes a mounting clip 530 for engaging the edge portion 532 of the stiffener 522 associated with the side sill 102 (FIGS. 22 and 20). 23). 24 and 25 show the attachment of the reinforcing member 400 to the reinforcement 522 associated with the side sill 102. As shown, the fastener 516 provided in the clip housing 500 is inserted through the opening 520 provided in the reinforcing member 522. An edge portion 532 of the reinforcing member 522 is inserted into a notch provided in the reinforcing member 402 and engaged with a mounting clip 530 provided on the bracket 470.

  Similar to the reinforcement member 120, the frame 406 includes at least one protrusion 540 that extends outwardly from the sidewall 424. The protrusion 540 is dimensioned to be received in the channel 160 defined in the outer panel member 122 of the side sill 102. As shown, a plurality of spaced apart protrusions 540 are arranged along the frame 406, but this is not essential. Alternatively, the frame 406 comprises a single elongated protrusion that extends substantially along the length of the frame. The adhesive 406 is provided on the outer surface of the protrusion 540.

  Referring to FIGS. 26 and 27, another embodiment of a structural member or reinforcement member 560 for the A-pillar 104 is shown. Similar to the reinforcement member 220, the reinforcement member 560 includes a reinforcement 562 having a honeycomb structure with a plurality of openings oriented substantially perpendicular to the longitudinal axis of the A pillar 104. An adhesive 566 is fixed to the reinforcing material 562. Adhesive 566 is similar to adhesive 272. The frame 570 is fixed to the reinforcing material 562. The frame 570 includes a base wall 572 and opposing side walls 574 and 576 connected to the base wall 572. According to one aspect, the side walls 574, 576 are hinged to the base wall 572, but this is not required. Base wall 572 is defined by a pair of spaced apart longitudinal members 580, 582 and a plurality of transverse members 584 extending between longitudinal members 580, 582. Tab 586 extends outwardly from longitudinal member 582.

  At least one base clip 590 is provided on the base wall 572 to secure the reinforcement 562 to the frame 570. As illustrated, a pair of base clips 590 are provided on the base wall 572, and each base clip 590 is installed in a notch 592 formed in the base wall 572. Each base clip 590 is connected to the base wall 572 by a movable member 596. The movable member 596 moves the base clip 590 in a direction away from the frame 570 so that the reinforcing material 562 can be arranged on the frame, and moves the base clip 590 in a direction toward the frame 570 to engage with the reinforcing material 562. It is comprised so that it may be in a state (FIG. 29 and FIG. 30). As shown, each movable member 596 has a bow tie shape and is defined by a pair of opposing loop members 600, 602 that can move the clip 590 away from the base wall 572. Has been. Since the loop members 600, 602 are at least partially elastic, the loop members return to the base wall 572 when extended. In order to place the stiffener 562 on the base wall 572, the edge of the stiffener 562 is placed on the tab 586. The base clip 590 is moved in a direction away from the frame 570, and then the reinforcing member swings downward and is placed on the base wall 572. When the base clip 590 is released and the extended loop members 600 and 602 return to the initial position, the base clip 590 engages with the reinforcing material 562.

  Each of the side walls 574 and 576 of the frame 570 is configured to engage the reinforcing material 562 at a position transverse to the position of the adhesive 566 provided on the reinforcing material 562. As described above, the side walls 574, 576 are hinged to the base wall 572, and at least one of the side walls includes a locking device to maintain a substantially vertical state with respect to the base wall 572. Specifically, referring to the side wall 574 shown in FIG. 31, the side wall 574 includes a movable portion 610 and a fixed portion 612. The movable portion 610 has a notch 614 sized to accommodate the fixed portion 612 and a flange 616 extending from the movable portion to engage the reinforcing material 560. The locking device 620 is provided in the movable part 610 adjacent to the notch 614. According to one aspect, the locking device 620 is provided with a clip 622 that extends into the notch 614, which is at least partially received in a corresponding opening 624 provided in the securing portion 612. The fixed portion 612 is an inclined portion that allows the clip 622 of the locking device 620 to easily slide into the opening 624 when the movable portion 610 moves upward with respect to the base wall 672 and engages with the reinforcing member 560. 626.

  32 and 33 show the reinforcing member 560 secured to a portion of the A pillar 104. The base wall 572 of the frame 570 includes a fastener 630 such as an arrowhead fastener that protrudes through an opening 632 provided in the inner panel member 224. Accordingly, the reinforcing member 560 is placed in the A pillar 104.

  The present disclosure is a method for strengthening a hollow structural member of a vehicle body, comprising the steps of providing a reinforcing member having a honeycomb structure having a plurality of openings, and for engaging with a part of an inner surface of the hollow structural member. Securing an activatable adhesive to the reinforcement so as to expand outwardly, and securing a frame partially configured to substantially conform to the shape of the inner surface of the hollow structural member to the reinforcement. The method further includes the steps of: inserting the reinforcing member into the hollow structural member together with the frame; and providing a gap between the adhesive and the inner surface of the hollow structural member prior to activation of the adhesive. The method further includes directing the honeycomb opening substantially perpendicular to the longitudinal axis of the hollow structural member.

  From the foregoing description, it should be appreciated that the use of a honeycomb structure formed of aluminum or an aluminum alloy imparts high strength to the structural member while maintaining lightweight properties. When an adhesive is used as a means for covering the opening of the honeycomb structure, the reinforcing member can be kept light by preventing accumulation of electrodeposition coating in the honeycomb structure. The adhesive on the reinforcing member of the reinforcing member creates a barrier between the reinforcing material and the structural member material that were in contact without the adhesive. The adhesive also has a high ductility to disperse the load well along the entire longitudinal axis of the reinforcement. As an example, due to high ductility, the adhesive provided on the reinforcing member can be compressed when an impact is applied to the structural member, such as a side impact on the side sill. This compression of the adhesive maintains the adhesion of the adhesive to the inner surface of the structural member and the reinforcement of the reinforcing member. Thereby, the adhesive can disperse the impact load through the reinforcing material. A stiffener that increases the load on the structural member may distribute the load through the structural member. Also, the frame can be suitable for various purposes. The first purpose is to suppress the adhesive and prevent high temperature flow. The second objective is to assemble the entire system so that it can be handled without compromising the surface properties of the adhesive. A third objective is to isolate the aluminum or aluminum alloy honeycomb structure from the inner surface of the structural member steel or alloy steel to prevent galvanic corrosion. Finally, a fourth object is to easily place the assembly in the cavity of the structural member and provide a gap for flowing electrodeposition paint between the reinforcing member and the inner surface.

  It should be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirable to be combined in many other different systems or applications. Also, various alternatives, modifications, changes or improvements not currently foreseen or anticipated in the present disclosure may be made subsequently by those skilled in the art which are intended to be covered by the claims.

Claims (20)

A car body,
A hollow structural member comprising a first metal or metal alloy and having an inner surface;
A structural reinforcing member disposed in the hollow structural member;
With
The structural reinforcing member is
Reinforcement,
Glue and
Frame,
With
The reinforcing material includes a second metal or metal alloy different from the first metal or metal alloy, and a gap is provided between the reinforcing material and the inner surface of the hollow structural member. ,
The adhesive is secured to the reinforcement, and the adhesive is substantially dry to the touch prior to activation and expands toward the inner surface to fill at least a portion of the gap. Can be activated and
The frame is fixed to the reinforcing material and is disposed between the reinforcing material and the inner surface of the hollow structural member in order to maintain the gap before expansion of the adhesive. Is a vehicle body characterized in that the reinforcing material is insulated from the hollow structural member.   The vehicle body according to claim 1, wherein the reinforcing member has a honeycomb structure in which a plurality of openings are defined, and the adhesive is disposed on both sides of the plurality of openings in the honeycomb structure.   The reinforcing member is inserted into the hollow structure member such that the plurality of openings of the honeycomb structure are oriented substantially perpendicular to a longitudinal axis defined by the hollow structure member. Car body described in.   The frame includes a base wall and opposing side walls movably connected to the base wall, and a portion of the frame substantially conforms to the shape of the inner surface of the hollow structural member. The vehicle body according to claim 1, which is configured.   A first end portion of each of the opposing side walls is hinged to the base wall, and the frame spans between the second end portions of the opposing side walls and the second end. The vehicle body of claim 4, further comprising at least one bracket connected to the portion.   The vehicle body according to claim 4, wherein the base wall of the frame is configured to be attached to a part of the inner surface of the hollow structural member.   The frame further includes a base wall clipped by a movable member, and the movable member moves the clip in a direction away from the base wall, arranges the frame on the reinforcing material, and faces the base wall. The vehicle body according to claim 4, wherein the vehicle body is configured to move the clip in a direction to engage with the reinforcing material.   The vehicle body according to claim 4, wherein the frame further includes a locking device for maintaining one of the opposing side walls in a substantially vertical state with respect to the base wall.   The vehicle body according to claim 1, wherein the honeycomb structure is formed of aluminum or an aluminum alloy, and the hollow structural member is formed of steel or alloy steel.   9. The vehicle body according to claim 8, wherein the frame is formed of a reinforced plastic material, and the frame provides an insulating material between the honeycomb structure and the hollow structural member in order to prevent galvanic corrosion. .   The hollow structural member is one of a pillar and a side sill of the vehicle body, an inner surface of the side sill includes a channel extending in a longitudinal direction, and the frame includes a protrusion corresponding to the shape of the channel. Item 1. The vehicle body according to Item 1.   The stiffener has a first surface and a second surface that is oriented substantially perpendicular to the first surface, and the frame includes the hollow structural member. Extending from the first surface to engage a first portion of an inner surface, and the adhesive is adapted to engage the second portion of the inner surface of the hollow structural member. The vehicle body according to claim 1, wherein the vehicle body can be activated so as to expand outward from the surface. A structural reinforcing member for a vehicle body provided with a hollow structural member having an inner surface,
Reinforcement,
Glue and
Frame,
With
The reinforcing material can be inserted into the hollow structural member in a state where a gap is formed between the reinforcing material and the inner surface, and the reinforcing material has a honeycomb structure having a plurality of openings, A reinforcing member is disposed in the hollow structural member such that the plurality of openings are oriented substantially perpendicular to the longitudinal axis of the hollow structural member;
The adhesive is directly fixed to the reinforcing material and is disposed so as to close open ends on both sides of the plurality of openings of the honeycomb structure, and the adhesive is substantially prior to activation. Is dry to the touch and can be activated to expand toward the inner surface to fill at least a portion of the gap;
The frame is fixed to the reinforcing material, and is disposed between the reinforcing material and the inner surface of the hollow structural member in order to maintain the gap before expansion of the adhesive, A structural reinforcing member, wherein a part of the frame is configured to substantially match the shape of the inner surface of the hollow structural member.   The hollow structural member includes a longitudinally extending channel defined on the inner surface, and the frame includes a protrusion extending at least partially into the channel. Structural reinforcement member.   The structural reinforcing member according to claim 14, wherein the adhesive is further fixed to the frame protruding portion and disposed between the frame and the inner surface of the hollow structural member.   The said frame is provided with the base wall and the opposing side wall hinge-connected to the said base wall, The said protrusion part is installed in one of the said base wall and the said side wall. Structural reinforcement member.   A clip is connected to the frame by a movable member. The movable member moves the clip in a direction away from the frame so that the frame can be disposed on the reinforcing member, and the clip is attached to the frame. The structural reinforcement member according to claim 13, wherein the structural reinforcement member is configured to be moved in a direction toward the direction of engagement with the reinforcing material.   The structural reinforcement member according to claim 13, wherein the frame is disposed on the reinforcing material substantially perpendicularly to the adhesive. A method for strengthening a hollow structural member of a vehicle,
Providing a reinforcement comprising a honeycomb structure having a plurality of openings;
Securing an activatable adhesive to the reinforcement to expand outwardly from the reinforcement and engage a portion of the inner surface of the hollow structural member;
Fixing a frame that is partially configured to substantially match the shape of the inner surface of the hollow structural member to the reinforcement;
Inserting the reinforcement together with the frame into the hollow structural member;
Providing a gap between the adhesive and the inner surface of the hollow structural member before the activation of the adhesive;
A method comprising the steps of:   20. The method of claim 19, comprising directing the opening in the honeycomb structure substantially perpendicular to the longitudinal axis of the hollow structural member.

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